A range extender system and vehicle

Abstract

The application relates to the technical field of electronic science, in particular to a range extender system and a vehicle, the range extender system comprising a front end cover, a shell with an intermediate partition plate and a rear end cover. The front end cover and the intermediate partition plate form a first cavity, the intermediate partition plate and the rear end cover form a second cavity, and the first cavity and the second cavity are respectively used for assembling a generator and a control unit, so that the range extender system integrates the generator and the control unit in the shell. In this way, the range extender system is highly integrated, the independent closed shells for the generator and the control unit are not needed, the number of redundant components and the connection steps are reduced, the complexity of the assembly process is reduced, the overall volume and weight of the range extender system are greatly reduced, and the utilization rate of the vehicle cabin space is improved.

Description

Technical Field

[0001] This application relates to the field of electronic science and technology, and in particular to a range extender system and vehicle. Background Technology

[0002] As one of the key components of range-extended new energy vehicles, the range extender mainly converts the mechanical energy of the engine into electrical energy through a generator (Generator Motor, GM) to provide power to the vehicle or charge the vehicle battery.

[0003] Existing range extender systems typically include a single generator (GM) unit or a combined GM and inverter (INV) structure. However, the generator and inverter in existing range extenders require separate enclosed mounting housings. For example, the stator assembly in the generator needs an independently designed mounting housing, and the inverter also needs a separate mounting housing compared to the GM unit. This repetitive design of multiple housing structures inevitably increases the overall size and weight of the range extender system, reduces space utilization, and makes the system structure and assembly process too complex, thus reducing the reliability and overall performance of the range extender system. Summary of the Invention

[0004] This invention provides a range extender system and vehicle to reduce the overall size and weight of the range extender and improve its reliability and overall performance.

[0005] In a first aspect, this application provides a range extender system, the system comprising a front cover, a housing, and a rear cover, wherein,

[0006] The front end cover and the middle partition of the housing form a first cavity, and the middle partition and the rear end cover form a second cavity. The first cavity and the second cavity are respectively used to assemble the generator and the control unit, so as to integrate the generator and the control unit into the housing.

[0007] Optionally, the stator assembly of the generator is connected to the housing via a preset connection method, which includes an interference fit or a bolted connection.

[0008] Optionally, the core of the stator assembly forms a cooling oil channel with the inner wall of the housing, the cooling oil channel is used to cool the generator, and the intermediate partition is used to prevent the cooling oil in the cooling oil channel from entering the second cavity.

[0009] Optionally, the system further includes an oil pump configured in a side chamber of the control unit.

[0010] Optionally, the rotor assembly of the generator is connected to the oil pump via the tail end of the shaft, so as to drive the oil pump shaft to rotate via a connecting mechanism.

[0011] Optionally, the control unit includes an inverter, an engine control unit, and a vehicle control unit; wherein,

[0012] The inverter is used to convert the alternating current from the generator into direct current and store the direct current in the battery;

[0013] The engine control unit is used to acquire the operating status of the engine and perform relevant control on the engine;

[0014] The vehicle control unit is used to control the various functional units of the vehicle.

[0015] Optionally, the inverter, the engine control unit, and the vehicle control unit are configured on a single circuit board and share a microcontroller chip.

[0016] Optionally, the housing further includes cooling channels disposed inside the housing for cooling the control unit.

[0017] Optionally, the cooling water channel is also used for:

[0018] Cooling water is transmitted to the control unit to water-cool the various components of the control unit;

[0019] The cooling water is transferred to a heat exchanger to cool the generator's cooling oil. Based on the heat exchanger, the cooling water is then transferred to a coolant circulation system to obtain cooled water, thus achieving water-cooled circulation. The heat exchanger connects the cooling water passage and the cooling oil passage.

[0020] Optionally, the cooling oil passage is also used for:

[0021] The water-cooled cooling oil is transferred to the stator assembly to perform oil cooling on the stator assembly;

[0022] Based on the oil pump, high-temperature oil is transferred to the heat exchanger to obtain water-cooled oil, thereby realizing oil cooling cycle.

[0023] Secondly, this application provides a vehicle that includes the range extender system described in the first aspect above.

[0024] The beneficial effects of this invention are as follows:

[0025] This application provides a range extender system, which includes a front cover, a housing with a middle partition, and a rear cover. The front cover and the middle partition of the housing form a first cavity, and the middle partition and the rear cover form a second cavity, respectively used for assembling a generator and a control unit. This allows the range extender system to integrate the generator and control unit within the housing, achieving a high degree of integration while eliminating the need for separate enclosed housings for the generator and control unit. This reduces the number of redundant components and connection steps, lowers the complexity of the assembly process, and significantly reduces the overall size and weight of the range extender system, improving the utilization rate of the vehicle's engine compartment space. Attached Figure Description

[0026] To more clearly illustrate the technical solutions in the embodiments of this application or related technologies, the drawings used in the description of the embodiments or related technologies will be briefly introduced below. Obviously, the drawings described below are only embodiments of this application. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0027] Figure 1 A cross-sectional schematic diagram of a range extender system structure provided in this application embodiment;

[0028] Figure 2 This is a side view of a range extender system provided in an embodiment of this application.

[0029] Figure 3 This is a schematic diagram of the structure of a mechanical pump provided in an embodiment of this application;

[0030] Figure 4 A top view schematic diagram of a range extender system provided in an embodiment of this application;

[0031] Figure 5 A schematic diagram of the flow direction of a cooling water channel provided in an embodiment of this application;

[0032] Figure 6 This is a schematic diagram of the flow direction of a cooling oil passage provided in an embodiment of this application. Detailed Implementation

[0033] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application. Unless otherwise specified, the embodiments and features in the embodiments of this application can be arbitrarily combined with each other. Furthermore, although a logical order is shown in the flowchart, in some cases, the steps shown or described may be performed in a different order than that shown here.

[0034] The terms "first" and "second" in the specification, claims, and accompanying drawings of this application are used to distinguish different objects, not to describe a specific order. Furthermore, the term "comprising" and any variations thereof are intended to cover non-exclusive protection. For example, a process, method, system, product, or device that includes a series of steps or units is not limited to the listed steps or units, but may optionally include steps or units not listed, or may optionally include other steps or units inherent to these processes, methods, products, or devices. The term "multiple" in this application can mean at least two, for example, two, three, or more, and this application does not impose limitations.

[0035] The term "and / or" in the embodiments of this application is merely a description of the association relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, and B existing alone. Additionally, the character " / " in this document generally indicates that the preceding and following related objects have an "or" relationship.

[0036] It is understood that the following specific embodiments of this application involve vehicle operation data and other related data. When the various embodiments of this application are applied to specific products or technologies, relevant licenses or consents are required, and the collection, use, and processing of related data must comply with the relevant laws, regulations, and standards of the relevant countries and regions. For example, relevant volunteers can be recruited and agreements can be signed to authorize their data, thereby enabling the implementation using the data of these volunteers; or, implementation can be carried out within an authorized organization, using data from members of the organization to implement the following implementation methods for data management; or, the relevant data used in the specific implementation may be simulated data, such as simulated data generated in a virtual scene.

[0037] The design concept of the embodiments of this application will be briefly introduced below.

[0038] As a key component of range-extended electric vehicles, the range extender primarily converts the mechanical energy of the engine into electrical energy through the generator (GM), providing power to the vehicle or charging its battery. Related technologies typically include a single GM unit or a combined GM and inverter structure. However, in such range extenders, the generator and inverter require separate enclosed housings. For example, the stator assembly in the GM needs a separately designed and mounted housing, and the inverter also requires a separate housing compared to the GM unit. This repetitive design of multiple housings and dispersed components inevitably increases the overall size and weight of the range extender system, reduces space utilization, and leads to overly complex system structure and assembly processes, reducing reliability and overall performance. Such a simple and low-integration range extender system also struggles to support vehicle intelligence and functional expansion, failing to meet the practical demands for high efficiency, low cost, and multi-functionality.

[0039] In view of the above problems, this application provides a range extender system, which includes a front cover, a housing with a middle partition, and a rear cover. The front cover and the middle partition of the housing constitute a first cavity for the generator, and the middle partition and the rear cover constitute a second cavity for the control unit. This integrates the generator and control unit within the housing, achieving a high degree of integration and enabling the range extender system to support vehicle intelligence and functional expansion, meeting the practical needs of high efficiency, low cost, and multifunctionality. Furthermore, it eliminates the need for separate enclosed housings for the generator and control unit, reducing the number of redundant components and connection steps, lowering the complexity of the assembly process, and significantly reducing the overall size and weight of the range extender system. This improves the utilization rate of the vehicle's engine compartment space, as well as the reliability and overall performance of the range extender system.

[0040] The following is a brief introduction to the application scenarios to which the technical solutions of the embodiments of this application are applicable. It should be noted that the application scenarios described below are only for illustrating the embodiments of this application and are not intended to limit the scope. In specific implementation, the technical solutions provided by the embodiments of this application can be flexibly applied according to actual needs.

[0041] The solutions provided in this application are applicable to the design of range extender systems for most vehicles, reducing the overall size and weight of the range extender, improving the structural compactness and assembly efficiency of the vehicle, and reducing the overall vehicle manufacturing cost. For example, when the engine and range extender system are axially arranged, and the axial dimensions are limited by the vehicle's engine compartment space, the housing provided in this application can reduce the design of independent housings and the dispersed layout of components, optimize the structural design of the generator and control unit in the range extender, minimize the overall size and weight of the range extender system, and improve the system's space utilization and integration level.

[0042] Of course, the methods provided in this application are not limited to the above-described application scenarios, and can also be used in other possible application scenarios. This application does not impose any limitations. The functions that each device can achieve in the above application scenarios will be described in subsequent method embodiments, and will not be elaborated upon here.

[0043] The following describes the systems and methods provided by exemplary embodiments of this application in conjunction with the application scenarios described above and with reference to the accompanying drawings. It should be noted that the application scenarios described above are only shown to facilitate understanding of the spirit and principles of this application, and the embodiments of this application are not limited in any way in this respect.

[0044] refer to Figure 1 and Figure 2 As shown, Figure 1 This is a cross-sectional schematic diagram of a range extender system structure provided in an embodiment of this application. Figure 2 This is a side view of a range extender system provided in an embodiment of the present application. The range extender system includes:

[0045] (1) The generator is integrated into the first cavity of the housing and is mainly used to convert the mechanical energy output by the engine into electrical energy.

[0046] (2) The control unit is integrated into the second cavity of the housing and is mainly used to control and manage the generator, engine and vehicle to ensure the efficient and stable operation of the range extender system.

[0047] (3) The front cover, together with the middle partition of the housing, forms the first cavity for assembling the generator.

[0048] (4) A housing with a central partition for integrating the generator and control unit into the housing.

[0049] (5) The rear end cover, together with the middle partition of the housing, forms a second cavity for assembling the control unit.

[0050] In this way, the generator and control unit no longer need to be enclosed in separate housings, avoiding redundant design of the housing structure, achieving a high degree of integration of the range extender system, reducing the structural volume of each component and external wiring connections, and reducing the overall size and weight of the range extender system.

[0051] Specifically, the front cover protects and seals the first chamber of the generator and provides support for the engine's mechanical connections. Its flange face is bolted to the engine block flange, forming a closed chamber that provides mounting space for the engine's flywheel. The intermediate partition of the housing also provides support for the installation space of the control unit and prevents coolant from entering the control unit's chamber. The rear cover protects and seals the second chamber of the control unit.

[0052] In one possible implementation, the housing in this application embodiment can be an integrated housing. Compared with the traditional split housing, the shared integrated housing can not only reduce the weight of the range extender, but also simplify the assembly process and further reduce the process cost.

[0053] In one possible implementation, the stator assembly of the generator in this application can be connected to the housing via a preset connection method. The preset connection method in this embodiment includes interference fit or bolted connection, etc. Through interference fit or bolted connection, a tight connection with the housing can be achieved, ensuring that the stator assembly maintains a precise position during operation and improving the generator's operational reliability.

[0054] Specifically, an interference fit refers to a stator assembly where the outer diameter of the stator core is designed to be within the same diameter as the housing, allowing the stator core to be tightly fixed to the inner wall of the housing through heat treatment or cold shrinkage. For example, the stator assembly can be installed after heating the housing to expand it, and a tight interference fit can be achieved after cooling; or the stator core can be installed into the housing after cooling and returning to room temperature to form an interference fit. A bolted fit refers to fixing the stator core to the pre-set mounting holes in the housing using bolts, ensuring a stable installation and facilitating maintenance.

[0055] It is worth mentioning that, according to specific design requirements, material properties, process conditions and application scenarios, other suitable preset connection methods can be selected in the embodiments of this application, such as welding, bonding, snap-fitting, riveting, threaded connection, pin connection, press-fitting connection, key connection, elastic connection, magnetic connection, tenon and mortise connection, heat-fitting connection, clamping connection, nested connection and composite connection, etc., and the embodiments of this application do not make specific limitations in this regard.

[0056] In one possible implementation, the core of the stator assembly in this application can form a cooling oil channel with the inner wall of the first housing. The cooling oil channel is used to cool the generator, and the intermediate partition is used to prevent the cooling oil in the cooling oil channel from entering the second cavity.

[0057] Specifically, the outer diameter of the stator core can be designed as a special passage to form a closed loop between it and the shell, i.e., a cooling oil channel. This allows the cooling oil to flow through the cooling oil channel and spray the stator windings through small holes at the ends of the core, thereby achieving efficient cooling of the stator and windings.

[0058] In one possible implementation, this application embodiment takes into account the different heights of the windings at both ends of the stator, and can also achieve different spray angles of oil by adjusting the misalignment of the oil spray holes of multiple iron cores on the end face of the iron core. Such an innovative design of the outer diameter of the iron core and the oil circuit design can greatly reduce the radial dimension of the range extender system and improve the cooling efficiency.

[0059] In one possible implementation, considering the axial arrangement of the engine and range extender system, the axial dimension of the range extender system will be limited by the vehicle's engine compartment space. Therefore, the axial dimension of the range extender system needs to be shortened as much as possible to meet the optimization requirements of the vehicle's space layout. In this embodiment, the control unit is laterally arranged within the range extender system housing, ensuring that the control unit maintains an axial arrangement with the GM (Gateway Unit). This effectively reduces the size of the range extender system in the vertical direction (Z-direction) and achieves maximum space utilization in the lateral direction (Y-direction) and axial direction (X-direction). This optimizes the spatial layout of the range extender system, improves its compatibility with the vehicle's engine compartment, further reduces the size and weight of the range extender system, simplifies the assembly process, and reduces production and installation costs.

[0060] In one possible implementation, the control unit in this embodiment may include an INV, an engine control unit (ECU), and a vehicle control unit (VCU). That is, the range extender system in this embodiment highly integrates the GM, INV, ECU, and VCU into a four-in-one system, further improving the integration level of the range extender. The control unit integrates three control subunits: INV, ECU, and VCU, thereby realizing the control functions of the generator, engine, and vehicle. Specifically, the INV converts the alternating current (AC) from the generator to direct current (DC) and stores the DC in the battery pack; the ECU acquires the engine's operating status and monitors and controls the engine; and the VCU is responsible for the coordination and management between vehicle modules and performs relevant control over the various functional units of the vehicle.

[0061] In one possible implementation, the inverter, engine control unit, and vehicle control unit in this application embodiment are configured on a single circuit board and share a microcontroller chip.

[0062] Specifically, the control unit in this embodiment not only integrates the physical structures of sub-control units such as INV, ECU, and VCU into the second housing, but also integrates the circuits of the ECU, GCU, and VCU onto the same printed circuit board assembly (PCBA) through circuit design and a multi-module shared chip approach. This three-in-one structure, sharing the PCBA, chip, and related electronic hardware, not only improves component utilization and reduces space occupancy and hardware costs, but also deeply integrates the software architecture, shortens response time, and improves system fault tolerance and reliability.

[0063] In one possible implementation, both the generator and controller cavities in this application can be designed as circular to further reduce the hardware surface volume, and the PCBA board is also designed as circular accordingly. This fully utilizes the circular cavity area while ensuring that the cavity area is minimized, which not only realizes the arrangement of hardware boards, but also makes the shape more aesthetically pleasing.

[0064] In one possible implementation, the control unit in this application embodiment may further include a filter assembly, a power module, a printed circuit board (PCB) assembly, a water-cooled plate assembly, low-voltage connectors, and high-voltage connectors, all of which are bolted to the housing. The filter assembly is used to stabilize the current and reduce electrical noise; the power module is used to convert three-phase AC power into DC power; the PCB assembly serves as a hardware platform and can integrate various control circuits; the water-cooled plate assembly is used to cool the power module and capacitors, maintaining the system temperature; and the low-voltage connectors and high-voltage connectors are used to connect low-voltage control signals and high-voltage power supply, respectively.

[0065] Specifically, in this embodiment, the control unit can be arranged from bottom to top with capacitors, water-cooled plate assembly, power module, support plate and PCB assembly. This arrangement allows the water-cooled plate assembly to cool the capacitors and power module at the same time, improving the system's heat dissipation efficiency.

[0066] In one possible implementation, the range extender system in this application embodiment can also fix the high-voltage terminal block to the housing with bolts and seal it with the housing using a sealing ring, thereby preventing the cooling oil in the GM cavity from entering the cavity of the control unit.

[0067] Specifically, the copper busbars at both ends of the high-voltage terminal block can be connected to the three-phase output lines of the GM stator assembly and the copper busbars of the INV power module respectively via bolts. This direct connection method of the copper busbars can reduce the length of the copper busbars, further reducing the size of the range extender system in the lateral direction (Y direction), thereby reducing the overall cost and weight of the range extender system.

[0068] In one possible implementation, the range extender system in this application embodiment further includes an oil pump, which is configured in the side chamber of the control unit. This allows for maintenance of the oil pump from the controller side chamber without disassembling the GM, improving the ease of maintenance.

[0069] In one possible implementation, the oil pump in this application embodiment can be a mechanical oil pump, an electronic oil pump, etc., and this application embodiment does not specifically limit this. A mechanical oil pump is directly driven by the engine, has a simple structure, low cost, and is particularly suitable for applications where the engine frequently starts and stops in range-extended systems, offering high reliability. An electronic oil pump is driven by an electric motor, can be independently controlled, and can precisely adjust oil pressure and flow. In range-extended systems, it can optimize energy consumption, adapt to electrification requirements, and is particularly suitable for pure electric mode applications.

[0070] For details, please refer to Figure 3 The diagram shows a structural schematic of a mechanical pump provided in an embodiment of this application. The motor rotor shaft is one of the core components of the GM (Genius Motor), used to convert the mechanical energy of the engine into rotational motion within the motor and drive the rotor assembly. In this embodiment, the tail end of the motor rotor shaft is directly connected to the oil pump shaft of the mechanical oil pump via a contoured connection structure, providing power to drive the mechanical oil pump. This further simplifies the mechanical structure of the range extender system and avoids additional independent drive components. The oil pump shaft is the core transmission component of the mechanical oil pump, used to transmit the rotational power of the motor rotor shaft to the inner rotor of the mechanical oil pump, completing the oil suction and pressure processes. By ensuring the alignment accuracy between the rotor tail end and the oil pump, transmission efficiency can be improved, and vibration and wear can be reduced. The mechanical pump is the core component for cooling and lubrication in this embodiment, used to achieve the suction, pressure delivery, and circulation of cooling oil, ensuring the cooling of the generator stator assembly and system lubrication. By combining the mechanical oil pump with the cooling oil circuit, this application can further reduce external oil circuit connections, reduce the risk of system oil leakage, and provide stable cooling and lubrication support for system operation. Mechanical pump cover plates are used to seal the installation chamber of mechanical pumps, ensuring that the mechanical pumps are isolated from the outside world, and at the same time fixing the position of the mechanical pumps.

[0071] In one possible implementation, the rotor assembly of the generator in this application can be connected to the oil pump via the tail end of the shaft to drive the oil pump shaft to rotate via a connecting mechanism.

[0072] Specifically, the GM rotor assembly's shaft is splined to the engine and drives the core assembly to rotate via the rotor hub. The mechanical oil pump is directly driven by the tail end of the rotor assembly's shaft. A contour-following connection structure transmits the rotational power of the rotor assembly's shaft to the mechanical oil pump shaft, thereby driving the inner rotor to rotate and achieving the oil suction and pressure functions. Furthermore, the mechanical oil pump can be installed later than the stator assembly, utilizing the alignment pin at the tail end of the generator rotor shaft to ensure precise alignment between the oil pump shaft and the rotor shaft, simplifying the mechanical oil pump assembly process.

[0073] In one possible implementation, refer to Figure 4 The diagram shown is a top view of a range extender system provided in an embodiment of this application. Figure 4It includes electrical connectors such as a control unit, heat exchanger, oil filter, T+T connectors, and low-voltage connectors. The heat exchanger connects to the cooling water and oil circuits, receiving cooling water from the control unit's water-cooled plate assembly and cooling the high-temperature oil. This cooled oil is then circulated to the stator assembly, effectively reducing the GM's operating temperature, ensuring system heat dissipation stability, and improving reliability and lifespan. Furthermore, through the heat exchanger and mechanical oil pump, the cooling oil flows from the mechanical oil pump through the stator assembly's core and windings, returning to the heat exchanger. After being cooled again by the heat exchanger, it re-enters the mechanical oil pump, forming a highly efficient closed-loop lubrication circuit. This ensures system stability and reliability, extends component life, and reduces the risk of oil leaks or oil circuit blockages. The oil filter filters the cooling oil, ensuring its cleanliness, improving the reliability of oil circulation, and preventing impurities from causing wear on the components. It can be a suction filter or a pressure filter for the GM's return oil tank. The T+T connector can be installed facing the battery pack, connecting the generator and battery pack via high-voltage lines to shorten the high-voltage wiring harness length and high-voltage power transmission path, thereby reducing power loss. Low-voltage connectors are used for low-voltage signal transmission, such as control and communication signals, and can be arranged vertically (Z-direction) for easy vehicle assembly.

[0074] In one possible implementation, the housing in this application embodiment further includes cooling water channels for cooling the control unit. By placing the cooling water channels inside the integrated housing, the cooling pipeline is internalized, reducing external cooling pipeline connections, lowering costs, improving system sealing, preventing coolant leakage, and increasing cooling efficiency, ensuring stable system operation under high load conditions.

[0075] In one possible implementation, the cooling water channel in this application embodiment can transmit cooling water to the control unit to water cool the components of the control unit, and then transmit the cooling water to the heat exchanger to water cool the generator's cooling oil. Through the heat exchanger connecting the cooling water channel and the cooling oil channel, the cooling water is transmitted to the coolant circulation system to obtain cooled water, thereby realizing water cooling circulation.

[0076] For details, please refer to Figure 5 The diagram shown is a flow diagram of a cooling water channel provided in an embodiment of this application. The cooling water can first pass through the water-cooled plate assembly of the control unit to cool the power module and capacitor, and then enter the heat exchanger to cool the GM's cooling oil. Finally, it returns to the vehicle's coolant circulation system through the outlet of the heat exchanger.

[0077] In one possible implementation, the cooling oil channels in this embodiment can transfer water-cooled cooling oil to the stator assembly for oil cooling. A mechanical oil pump then transfers the high-temperature oil to a heat exchanger to obtain water-cooled oil, thus achieving an oil-cooling cycle. In this way, this application addresses the different needs of the control unit and generator by employing water cooling and oil cooling respectively. The water-cooled plate assembly of the control unit simultaneously cools the power module and capacitor, improving heat dissipation efficiency. The generator cools the stator windings and lubricates the bearings through oil injection holes, extending component lifespan and further improving the cooling efficiency of the range extender system.

[0078] For details, please refer to Figure 6 The diagram shows the flow direction of a cooling oil channel according to an embodiment of this application. Cooling oil is drawn into the suction chamber by a mechanical oil pump and flows out from the pressure chamber into an oil filter for filtration. The filtered cooling oil enters a heat exchanger where it is cooled by cooling water. The cooled oil then flows through the outer diameter oil channels of the stator core to cool the stator core, and simultaneously sprays oil through oil holes on the end face of the core onto the stator windings, achieving cooling of the stator windings. The high-temperature oil is again cooled by the mechanical oil pump in the heat exchanger, and then further cools the GM (Gross Mechanism), forming an oil-cooling cycle. Simultaneously, the oil flows through the bearing lubrication channels, providing active lubrication to the bearings, resulting in excellent lubrication and cooling effects.

[0079] For ease of description, the above sections are divided into functional units (or modules) and described separately. Of course, in implementing this application, the functions of each unit (or module) can be implemented in one or more software or hardware components. Those skilled in the art will understand that various aspects of this application can be implemented as systems, methods, or program products. Therefore, various aspects of this application can be specifically implemented in the following forms: a completely hardware implementation, a completely software implementation (including firmware, microcode, etc.), or a combination of hardware and software implementations, collectively referred to herein as "circuit," "module," or "system."

[0080] It should be noted that although several units or sub-units of the device have been mentioned in the detailed description above, this division is merely exemplary and not mandatory. In fact, according to embodiments of this application, the features and functions of two or more units described above can be embodied in one unit. Conversely, the features and functions of one unit described above can be further divided and embodied by multiple units.

[0081] Furthermore, although the operations of the method of this application are described in a specific order in the accompanying drawings, this does not require or imply that these operations must be performed in that specific order, or that all the operations shown must be performed to achieve the desired result. Additionally or alternatively, certain steps may be omitted, multiple steps may be combined into one step, and / or one step may be broken down into multiple steps.

[0082] Those skilled in the art will understand that embodiments of this application can be provided as methods, systems, or computer program products. Therefore, this application can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, this application can take the form of a computer program product embodied on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0083] Although preferred embodiments of this application have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of this application.

[0084] Obviously, those skilled in the art can make various modifications and variations to this application without departing from the spirit and scope of this application. Therefore, if such modifications and variations fall within the scope of the claims of this application and their equivalents, this application also intends to include such modifications and variations.

Claims

1. A range extender system, characterized in that, The system includes a front cover, a housing, and a rear cover, wherein, The front end cover and the middle partition of the housing form a first cavity, and the middle partition and the rear end cover form a second cavity. The first cavity and the second cavity are respectively used to assemble the generator and the control unit, so as to integrate the generator and the control unit into the housing.

2. The system as described in claim 1, characterized in that, The stator assembly of the generator is connected to the housing through a preset connection method, which includes an interference fit or a bolted connection.

3. The system as described in claim 2, characterized in that, The core of the stator assembly forms a cooling oil channel with the inner wall of the housing. The cooling oil channel is used to cool the generator. The intermediate partition is used to prevent the cooling oil from the cooling oil channel from entering the second cavity.

4. The system as described in claim 1, characterized in that, The system also includes an oil pump, which is configured in the side chamber of the control unit.

5. The system as described in claim 4, characterized in that, The rotor assembly of the generator is connected to the oil pump via the tail end of the shaft, so as to drive the oil pump shaft to rotate through the connecting mechanism.

6. The system as described in claim 1, characterized in that, The control unit includes an inverter, an engine control unit, and a vehicle control unit; wherein... The inverter is used to convert the alternating current from the generator into direct current and store the direct current in the battery; The engine control unit is used to acquire the operating status of the engine and perform relevant control on the engine; The vehicle control unit is used to control the various functional units of the vehicle.

7. The system as described in claim 6, characterized in that, The inverter, the engine control unit, and the vehicle control unit are configured on a single circuit board and share a microcontroller chip.

8. The system as described in claim 1, characterized in that, The housing also includes cooling channels disposed inside the housing for cooling the control unit.

9. The system as described in claim 8, characterized in that, The cooling water channel is also used for: Cooling water is transmitted to the control unit to water-cool the various components of the control unit; The cooling water is transferred to a heat exchanger to cool the generator's cooling oil. Based on the heat exchanger, the cooling water is then transferred to a coolant circulation system to obtain cooled water, thus achieving water-cooled circulation. The heat exchanger connects the cooling water passage and the cooling oil passage.

10. The system as described in claim 3, characterized in that, The cooling oil passage is also used for: The water-cooled cooling oil is transferred to the stator assembly to perform oil cooling on the stator assembly; Based on the oil pump, high-temperature oil is transferred to the heat exchanger to obtain water-cooled oil, thereby realizing oil cooling cycle.

11. A vehicle comprising the range extender system as described in any one of claims 1 to 10.

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